Medical Device Engineer

MOHAMMAD ALI

*** ****** *****, *******, ** *****

Phone: 215-***-****, Cell Phone: 267-***-****

Email: ********@*****.***

SUMMARY OF SKILLS

Expertise in medical device and packaging products in the areas of plastic materials and processing techniques (extrusion,

coextrusion, thermoforming, injection molding, and blow molding). Diverse and extensive experience in multilayer

barrier and non barrier food packaging in the areas of material selection, formulations, sheet extrusion and

thermoforming, compounding, characterization, rheology and testing of plastic materials and finish articles. Strong

background in start up projects from R & D into manufacturing. Broad knowledge of management, supervising and

tooling, quality control, Six Sigma Green Belt, Design of Experiment (DOE) and Good Manufacturing Practice (GMP),

Food and Drug Administration (FDA) and Canadian Food Regulations and ISO-9000. Computer skills: Microsoft words

excel (spreadsheet) and CAD/CAM mold flow analysis.

PROFESSIONAL EXPERIENCE

Ethicon, Inc. family of Johnson & Johnson, Somerville, NJ 2007 to 2009 (Contract)

Packaging Engineer

• Created protocols for the sterilization and packaging validation, performed testing and analyzing the results and produced

protocol reports and recommendations. Coordinated out-sourcing of packaging material suppliers for multiple projects.

protocol

• Involved in the cost effective medical device packaging development in the areas of materials selection, evaluated

primary and secondary packaging performance under FDA and GMP guidelines

• Investigated and implemented new packaging materials, testing method and processes for new packages

development

• Performed packaging stability study and evaluate the shelf life of medical device products and assisted to

develop antibacterial packages and evaluated Triclosan (Irgacare MP) in biopolymers and packages

• Developed cold forming process for deep draw foil packages involved in mold modifications and material

selections.

• Set up and optimized the extrusion processes for the production of monofilament and evaluated the multifilament

biopolymer fibers and improved the physical properties of the fibers by orientation techniques.

• Performed synthesis and modification of biopolymers. Achieved faster absorption rate of suture and implantable

medical device products. Compounded biopolymers using twin extruder, improved the physical and mechanical properties

and minimized the residual content of monomer.

• Contributed in the development of adhesion prevention extruded cast film for the vivo and vitro test evaluations.

• Performed effectively within a team environment to resolve problems and to meet deadlines and multi-tasks environment.

Winpak Portion Packaging, Inc., Newtown, PA 2003 to 2006

Product Development Engineer

• Demonstrated technical support in the area of multi and mono layer products such as cups, trays and heat sealant

lids for manufacturing and development of food packaging applications.

• Analyzed and communicated results of development efforts and root cause investigations through frequent

reporting, written documentation and oral presentations.

• Created material and product specifications and approved supplier list for same as necessary for product

development and localization in timely manner.

• Recommended plastics materials selection, formulations of multilayer sheet structures, optimizing of

coextrusion, thermoforming and lamination processes.

• Saved manufacturing cost by reducing scraps that are generated from inline thermoforming process.

• Successfully performed trial runs of different sheet structures such as PP/EVOH/PP, PP/EVOH/PE,

PS/EVOH/PE, PP/PE, PS/PE and PET using in line thermoforming and lamination processes for various cup and tray

products.

• Developed PP barrier coffee cups and measured the puncturing force and OTR performance. The results are

patentable

• Gained FDA and Canadian Food Approval for the current and new food products. Issued FDA letter, maintained

food regulations of all container and lid products.

• Worked as a team member to support product group on development projects in the area of product design,

materials selection and processing skills and knowledge of tooling for thermoforming processes.

SABIC, Incorporated 2001 to 2002 (Contract)

Customer Technical Support

MOHAMMAD ALI PAGE # 2

• Provided customers technical support in the areas of troubleshooting of injection molding, blow molding and thermoforming

processes for PET container production. Coordinated with the customer to define the project scope, the product

specifications, product validation protocols, production requirements and the time frame for the various phases of

the project. Investigated customer complaints in timely manner and involved interface with quality assurance,

manufacturing plant, and marketing to improve quality of the current products.

W.R. Grace, Cambridge, MA 1997 to 2001

Processing Engineer

• Achieved new oxygen scavenging plastic materials development from concept to commercialization through

material selection, formulations, compounding, and molding to produce plastic beer bottles.

• Supervised technicians and managed multiple projects in timely manner and involved interface with internal and

external customers.

• Prepared formulations and compounded polyester, polyethylene vinyl alcohol, polyethylene, polypropylene,

nylons, EVA and PVC with scavenging additives using twin extruder. Improved oxygen-scavenging additives

feeding and mixing performance.

• Installed K-Tron feeder, take off machine and palletizer to start up twin extruder

compounding line.

• Studied the rheology behavior of polyolefin and adhesive materials to achieve minimum layer

thickness for multilayer package. Maintained good adhesion to metal substrates using lamination technique.

• Produced polyolefin and polyester films and investigated the oxygen scavenging and gas barrier

performance of multilayer food packages.

• Accomplished UV and moisture triggerable oxygen scavenging technology to increase the shelf life of

food/beverage products packaged in plastic containers.

• Performed DOE (Design of Experiment) to optimize variables that affect the oxygen scavenging

performance of polyester food packages and improved the product quality

Graham Packaging, York, PA 1994 to 1997

Processing Engineer

•Implemented a research and technical laboratory that allowed Graham Packaging internal capabilities such

as testing and analyzing current, future development and competitive mono and multilayers bottles/ preforms.

•Provided technical support to the PET division in developing material analysis systems and procedures of

both virgin and recycled plastics materials.

• Accomplished multilayer / barrier coating technology to increase shelf life of food/beverage products packaged in

plastic containers. Reduced cost of barrier packages.

• Measured the Intrinsic Viscosity (I. V.), glass transition temperature (T g) and crystallinity of PET

containers qualification and resins/flakes. Performed materials selection and worked closely with customers

in all areas of preform and bottle design.

USCI, C. R. Bard, Inc., Billerica, MA 1993 to 1994 (contract)

COMPOUNDER

•Performed mixing and compounded polyurethane powders with additives and pigments for single and multi-lumen tubing

for medical device applications. Improved output of the compounding line.

•Set and start up twin screw extruder. Initiated improvement of materials viscosity problem and reduced scraps

•Used Good Manufacturing Practice (GMP) and maintained the quality of single and multi-lumen tubing product

EDUCATION

University of Massachusetts Lowell, Massachusetts, MS in Plastics, 1995

University of Dhaka, Dhaka, Bangladesh, MS in Organic Chemistry, 1983

ADDITIONAL TRAINING

• Completed Health Care Compliance (HCC) Training by Ethicon Inc. a Johnson & Johnson Company, 2008

• Introduction to the Quality System Regulation (QSR) by Ethicon Inc. a Johnson & Johnson Company, 2008

• Completed ISO-9000 by Winpak Portion Packaging, 2004

• Six Sigma Green Belt training by W. R Grace, 2001

• Design of Experiment (DOE): Taguchi method, 2001, Echips by W.R. Grace Co. 1999 and KW Tunnell, 1996

PROFESSIONAL AFFILIATIONS

Member of Society of Plastics Engineer (SPE)

Member of American Chemical Society (ACS)

MOHAMMAD ALI PAGE # 2

PATENTS

“Oxygen-Scavenging Alkyd Resins in Food-Packaging Application.” Z. Jiang; A. Ranganathan; M. Ali. October 19, 1999. “Moisture

Triggerable Oxygen Scavenging Polymer for Food-Packaging Application.”J. Ciccone, M.Ali, May 24, 2000

PUBLICATIONS

R. D. Deanin and M. Ali, “Aromatic Organic Phosphate Oligomers As Flame Retardants in Plastics, “American Chemical Society,

Polymeric Material Science and Engineering; Preprint, 71, 237 (8/94).

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